1. Fuel Cell Systems Engineering, F06 Fuel Cell Systems Engineering Systems Engineering Process

2. Fuel Cell Systems Engineering, F06 Announcement Change of classroom to JEC4034 starting on Tuesday. For the class on Monday, September 11 th study the OTC Solicitation that will be distributed via email next week.

3. Fuel Cell Systems Engineering, F06 Lecture 2 Topics Re-cap of intro lecture topics Systems Engineering as a process/method When & how to apply the Systems Engineering Process Process inputs and outputs Group activity

4. Fuel Cell Systems Engineering, F06 Systems Engineering is a Process Systems Engineering is an interdisciplinary, iterative, structured process employed to increase the probability that a developed system meets the original user requirements.

5. Fuel Cell Systems Engineering, F06 Systems Engineering Objectives Reduce Cost Reduce Risks Increase Probability of Success

6. Fuel Cell Systems Engineering, F06 Defining the System A system is a complex set of interrelated components working together as an integrated whole toward some common objective.

7. Fuel Cell Systems Engineering, F06 This IS NOT a System 5 Cell PEMFC stack from TDM

8. Fuel Cell Systems Engineering, F06 This IS a System Plug Power’s GenSysTM 5KW System

9. Fuel Cell Systems Engineering, F06 Common Systems Elements Hardware Software People Environment Information Interfaces & integration with other systems A System of Systems

10. Fuel Cell Systems Engineering, F06 Hierarchy of System Levels System Subsystem Components Sub- components Parts RNG PEMFC System ThermalFuel Controls Reformer Documentation Stack Power Cond. End Plates Cells Manifolds Bi-Polar plates Cooling Plates Gaskets MEAs Seals Membrane GDL Catalyst Sub-gasket

11. Fuel Cell Systems Engineering, F06 Defining the “System” It is critical that the boundaries of the “box” around the system be clearly defined and understood. Failure to do so usually results in a system that does not meet the expectations of the user.

12. Fuel Cell Systems Engineering, F06 System Life Cycle A term used to describe the typical step- wise evolution of a new system from concept through development, production, deployment and operation, and eventual disposal or retirement. There are many different System Life Cycle Models, but all have similarities.

13. Fuel Cell Systems Engineering, F06 System Life Cycle Concept Development Post Development Engineering Development Needs Analysis Concept Exploration Concept Definition Advanced Development Engineering Design Integration & Evaluation Production Operation & Support Retirement Systems Engineering Stages Systems Engineering Phases

14. Fuel Cell Systems Engineering, F06 System Life Cycle And the life cycle of these two fuel cell systems will be much different. Plug Power’s GenSysTM 5KW System UltraCell’s 25W Portable System

15. Fuel Cell Systems Engineering, F06 When to Apply the SE Methodology? The amount and rigor of the application of systems engineering methods is usually related to the system complexity, and the probability and consequences of failure Space shuttle- very complex, low probability of failure, very high consequences MS Windows- moderate to high complexity, high probability of failure, low consequences FC system for space shuttle? UPS FC system?

16. Fuel Cell Systems Engineering, F06 Project Cost vs. Time Project cost- % Concept Dev. Engineering Dev. Post Dev. Retirement 20 100 80 60 40 Actual Cost Realized Final Cost Determined

17. Fuel Cell Systems Engineering, F06 SE Process- The 50,000ft View Requirements Analysis Functional Definition Physical Definition Design Validation Although the specific activities may change slightly depending on the particular system and developmental stage, the general process is similar. Process Inputs Process Outputs

18. Fuel Cell Systems Engineering, F06 An Iterative Process The Systems Engineering Process is an iterative process that is applied during each successive stage of the system life cycle. At each successive iteration the inputs and outputs become more refined and detailed.

19. Fuel Cell Systems Engineering, F06 Project Initiation Needs based development- –There is either a real or perceived shortcoming(s) with an existing system or process –Project is typically initiated by the user Opportunity based development- –The emergence of a new technology creates a new market opportunity (real or perceived) –Project is typically initiated by the system developer

20. Fuel Cell Systems Engineering, F06 Process Inputs User needs/objectives/requirements –Missions –Measures of effectiveness –Environments –Constraints Precursor system or technology Outputs from prior development efforts Program plans Specifications and standards

21. Fuel Cell Systems Engineering, F06 Requirements Analysis Organize inputs: needs; requirements; plans; schedule; models; precursor designs Understand the objectives in terms of the “why” associated with each requirement re: operational needs, constraints, environment, schedule, etc. e.g. “improved responsiveness” Clarify the user needs- “What” the system must do, and “how well” it must do it, e.g. –Increased range & speed; stop & fire within x sec.; day/night vision; on-board processors for critical functions Quantify the needs whenever possible

22. Fuel Cell Systems Engineering, F06 Functional Definition Translate all requirements into functional “what” statements. Typically action words are used, e.g. “stop and fire within x seconds.” Allocate functional requirements into basic functional elements, e.g. –Provide secure communications –Provide automated fuse setting –Provide automated location and direction data for armament –Provide for on-board ballistic computation Define functional interactions, e.g. commo. > location> ballistics > fuse setting

23. Fuel Cell Systems Engineering, F06 Physical Definition Translate functional requirements (“what”) into multiple technical approaches (“how”) Conduct trade-off analysis to determine ”best technical approach.” Best is determined at the system level by the best combination of performance, risk, cost and schedule, based on previously determined prioritized criteria (measures of effectiveness). Define the system design to the required level of detail.

24. Fuel Cell Systems Engineering, F06 Design Validation Does the selected design meet the requirements and constraints? –Models of system performance (physical, mathematical, simulations, logical) –Testing and analysis of results. Re-evaluate the requirements and constraints.

25. Fuel Cell Systems Engineering, F06 Process Outputs Refined plans Updated requirements Decision support information Results of analyses Designs Specifications

26. Fuel Cell Systems Engineering, F06 Situation Small gasoline engines, such as those on lawn mowers are a significant source of pollution. Small gasoline engines are not fuel efficient. Standard electric lawn mowers require an extension cord (hazard & inconvenient). Batteries do not have the power density needed for a lawn mower. A number of states are considering legislation that will impose emission standards and fuel economy standards on small gasoline engines. It is anticipated that legislation will drive the cost of lawnmowers up significantly.

27. Fuel Cell Systems Engineering, F06 Opportunity There is a perceived opportunity to develop a fuel cell powered lawn mower that will overcome the shortcomings of current lawnmowers.

28. Fuel Cell Systems Engineering, F06 Group Activity From the perspective of the user, what are the requirements associated with a fuel cell powered lawnmower? From the perspective of the developer, how would you go about determining IF there is a feasible (fuel cell) solution to the perceived need?